Can the automotive industry also operate in the space sector with its proven expertise? ZF is demonstrating that it can meet the stringent demands of the space industry.
Hardware-in-the-loop (HIL) simulation is a key test methodology for validating complex systems such as electronic control units (ECUs). Not only the software functionality is tested, but also the run-time behavior under real hardware conditions. This method has been standard practice at ZF for years – and is now successfully applied in cross-industry space projects.
The Mission: HIL Simulation for ATMOS Space Cargo
In April 2025, ATMOS Space Cargo successfully launched its PHOENIX 1 re-entry capsule as part of SpaceX’s Bandwagon-3 mission – marking a major milestone in European autonomous return capabilities. The mission was successful and achieved most of its main objectives, including the activation of critical subsystems and the transmission of telemetry and payload data.
ZF supported the development and validation of the onboard systems with a customized HIL simulation-as-a-service. The focus was on verifying the core functionality during orbit and recording telemetry data during flight.
A central element of the validation was the MA61C onboard computer, developed by Space Products and Innovation (SPiN), based on the tried-and-tested LEON 3 architecture. After successful tests in ZF’s HIL environment and the launch, the system reached Technology Readiness Level 9 (TRL 9) – the highest level of space validation according to the NASA and ESA definition.
This collaboration impressively highlights how ZF flexibly adapts its proven simulation solutions to the requirements of space travel – with precision, agility, and mission-specific validation.
From Concept to Orbit: End-to-End System Validation
With HiL Solutions, ZF offers comprehensive simulation options for validating complete satellite systems under real-time conditions. HIL simulation bridges the gap between virtual development and physical use – with rigorous testing in a controlled, realistic environment.
Thanks to many years of experience in the automotive industry and targeted adaptation of the test infrastructure, ZF also meets the high requirements of the aerospace industry. The range of services extends from model-in-the-loop (MIL) to software and processor-in-the-loop (SIL/PIL) and hardware-in-the-loop (HIL).
HIL-as-a-Service: Intelligent Tests, Faster Results
ZF's scalable HIL platform enables the real-time integration of system components in virtual controlled systems based on validated simulation models. This allows the entire system to be tested under realistic conditions – without any risk to the hardware or payload.
The early validation of control algorithms and position control systems significantly shortens commissioning and testing times. The combination of space travel requirements and automotive innovations leads to shorter development cycles, greater reliability, and a clear competitive advantage.
Simulation at the Highest Level: From MIL to HIL
ZF HiL Solutions cover the entire development spectrum – from the concept phase to final use. The offer benefits from industry-proven simulation solutions from dSPACE. The strengths at a glance:
- Multibody dynamics for complex scenarios such as rendezvous and docking, including the fluid dynamics of sloshing fuel – with the tried and tested simulation models from Astos Solutions
- Realistic sensor and actuator simulation including run-time error generation – with the dSPACE simulation platform SCALEXIO
- 3D visualization with the ASTOS software
- Integrated cybersecurity architectures, e.g., for ground station communication across the entire product lifecycle – using ZF expertise from the automotive world
"The flexibly configurable and freely scalable SCALEXIO simulation platform from dSPACE enables us to tailor our validation services precisely and individually to the specific requirements of our customers. This allows us to create customized solutions with maximum efficiency and quality."
Modern HIL Laboratory: Flexible, Scalable, Mission-Specific
The ZF HIL laboratory is based on a modular architecture with dSPACE SCALEXIO systems and supports a variety of interfaces – including analog, digital, RS232, SpaceWire, CAN, Ethernet, and MIL-STD-1553.
The SCALEXIO platform enables the realistic simulation of cameras, lidar, radar, magnetometers, and sun sensors. In combination with solutions from Astos Solutions – including leading software for the analysis and optimization of space missions – a high-precision environment is created for:
- Orbital dynamics
- Guidance, navigation, and control (GNC)
- Interaction with flexible structures
dSPACE's hypervisor technology enables the seamless integration of Linux-based real-time and non-real-time applications on the SCALEXIO simulation platforms – for maximum flexibility, openness, and efficiency in complex test environments. This allows the ASTOS software to be integrated directly into the HIL platform. The result: a powerful combination of dynamic models for complex space missions and deterministic real-time simulation in a closed loop with real controllers – the best of both worlds.
Accelerating Innovation - with HIL-as-a-Service
ZF HiL Solutions offer a modern, flexible test infrastructure without high investment costs. The leasing model enables predictable expenditure, location-independent collaboration, and parallel development through rapid control prototyping. Automated tests and fault simulations ensure reliable validation. From idea to release, ZF supports its customers with technical expertise – supported by the scalable SCALEXIO real-time systems from dSPACE as the technological basis of the HIL-as-a-service solution.
Oliver Maschmann, ZF
dSPACE MAGAZINE, PUBLISHED NOVEMBER 2025
ZF HiL Solutions: Efficient Validation of Innovation with HIL Simulation
With HiL Solutions, ZF offers companies from demanding industries such as aerospace access to a state-of-the-art hardware-in-the-loop (HIL) laboratory. The flexible infrastructure is managed by an experienced team of technical experts and enables efficient, low-risk system development and validation – without the need for high investments.
The Benefits at a Glance:
- Modern HIL laboratory without high investment costs
- Access to professional test infrastructure without capital commitment
- Cost-efficient leasing model
- Plannable expenditure and full budget control
- Flexible use: local and remote
- Optimal collaboration between distributed development teams
- Rapid control prototyping
- Parallel development of controllers and systems to accelerate development cycles
- Faster time to market
- Shorter development times and efficient test processes
- Early fault detection
- Thanks to advanced diagnostic functions for hardware and software
- Robust system validation
- Comprehensive fault simulations and automated test sequences
- Competent project support
- Expert advice and practical support throughout the entire project lifecycle
- Reliable development partner
- ZF HiL Solutions stand for quality, efficiency, and innovative strength in the development of complex systems
ATMOS Space Cargo: Europe's Pioneer for Orbital Return Logistics
Founded in 2023, ATMOS Space Cargo is a leading European space logistics start-up specializing in the development of return systems for orbital payloads from low Earth orbit (LEO). As a European private logistics provider for transportation to and from space back to earth, ATMOS aims to establish an independent infrastructure for the safe and efficient return of materials, experiments, and goods from space for research facilities, industrial customers, and safety-critical applications.
With the first orbital test of its PHOENIX 1 capsule, ATMOS has positioned itself as a leading innovator in re-entry technology among European space start-ups. The company sees itself as an important link between Earth and orbital space, contributing to the long-term scalability and autonomy of European space logistics and enabling cost-efficient and flexible access to space for industry, medicine, and research institutions.
